Allen-Bradley TLSZ User Manual

User Manual
Original Instructions
TLSZ Guardmaster Guard Locking Switch
Catalog Numbers 440G-TZS21UPRH, 440G-TZS21UPLH, 440G-TZS21UTRH, 440G-TZS21UTLH
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Table of Contents

Preface
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 1
General Description Guardmaster TLSZ Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Packaging Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 2
Installation General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Actuator/Target Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Allowable Approach Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Minimum Operating Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manual Override Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pair Proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Guide Repositioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Steel Locking Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Actuator Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 3
Wiring Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OSSD Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Auxiliary Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lock Command. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 4
Commissioning Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
First Time Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Learn First Target . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Learning Additional Targets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Commissioning Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power-up Self-check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 5
Functional Testing Testing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 3
Table of Contents
Chapter 6 Application and Wiring Examples
Diagnostics and Troubleshooting
Wiring to GLP Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Wiring to GLT Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Wiring to DI and EMD Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Wiring to DG Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring to CR30 Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wiring to 1734 POINT Guard I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Wiring to 1732 ArmorBlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Chapter 7
Tools Needed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Optional Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Step 1 — Status
Indicator OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Step 2 — Status Indicator Flashing Red at 4 Hz. . . . . . . . . . . . . . . . . . 45
Wrong Target. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Missing Target . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Target Not Mounted Correctly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Pair Proximity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Mechanical Pressure on Safety Gate . . . . . . . . . . . . . . . . . . . . . . . . . 47
Long Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Voltage Supply Dips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Rapid Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Step 3 - Status Indicator Flashes Red at 1 Hz . . . . . . . . . . . . . . . . . . . . 50
Capacitive Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Step 4 — Status Indicator Flashes Green at 1 Hz. . . . . . . . . . . . . . . . . 51
Step 5 — Flashing Red and Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Step 6 — Indicator Solid Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Step 7 — Other Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Distribution Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
GSR Relays on Power-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Appendix A
Specifications and Safety Ratings
4 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Safety Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Preface

Read this preface to familiarize yourself with the rest of the manual. It provides information concerning:
•Who would use this manual
•The purpose of this manual
• Related documentation
• Conventions used in this manual

Who Should Use This Manual

Purpose of This Manual

Conventions Used in This Manual

Use this manual to design, install, program, or troubleshoot systems that use the TLSZ Guardmaster® guard locking safety switches.
You are required to have a basic understanding of electrical circuitry and familiarity with safety-related control systems. If you do not, obtain the proper training before using this product.
This manual is a reference guide for the Guardmaster TLSZ guard locking switch. It describes the procedures you use to install, wire, and troubleshoot your switch. This manual:
• Explains how to install and wire your TLSZ switch,
• Provides an overview of the Guardmaster TLSZ guard locking switch.
The following conventions are used throughout this manual:
• Bulleted lists such as this one provide information, not procedural steps.
• Numbered lists provide sequential steps or hierarchical information.

Additional Resources

The following documents offers additional information about related Rockwell Automation products.
Resource Description
Guardmaster 440C-CR30 Configurable Safety Relay Wiring Diagrams, publication 440C-WD001
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1
Product Certifications website, rok.auto/certifications
Functional Safety Data Sheet, publication SAFETY-SR001
Industrial Automation Glossary, publication AG-7. 1
You can view and download publications at rok.auto/literature
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 5
Provides example wiring diagrams for the CR30 software configuration safety relay.
Provides general guidelines for installation of a RockwellAutomation® industrial system.
Provides declarations of conformity, certificates for the TLSZ guard locking switch.
Provides functional safety data and details for RockwellAutomation products.
Glossary of industrial automation terms and abbreviations
.
Preface

Terminology

The Industrial Automation Glossary contains terms and abbreviations used by Rockwell Automation to describe industrial automation systems. Below is a list of specific terms and abbreviations used in this manual.
NC No connection
N.C. (Normally Closed)
N.O. (Normally Open)
PLC A programmable logic controller or a programmable
PTL (Power to Lock)
PTL (Power to Release)
Reaction Time Describes the time between the true state of the input to
An electrical contact whose normal state (for example, no pressure or electrical potential applied) is in the closed position.
An electrical contact whose normal state (i.e., no pressure or electrical potential applied) is in the open position.
automation controller.
Apply 24V to the lock command to lock the switch. This command applies to the TLSZL switch.
Apply 24V to the lock command to unlock the switch. This command applies to the TLSZR switch.
the ON state of the output.
Response Time Describes the time between the trigger of the input to
the OFF state of the output. Throughout this manual, the safety outputs may be described as turning off immediately. This means that the safety outputs will turn off within the response time.
RFID Radio frequency identification.
OSSD (Output Signal Switching Device)
Standard coding Same as Low coding as defined in ENISO14119:2013
TLSZL TLSZ power-to-lock guard locking switch
TLSZR TLSZ power-to-release guard locking switch
Unique coding Same as High coding as defined in ENISO14119:2013
Typically a pair of solid-state signals pulled up to the DC source supply. The signals are usually tested for short circuits to the DC power supply, short circuits to the DC common, and short circuits between the two signals.
6 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
General Description
Chapter 1

Guardmaster TLSZ Overview

This Guardmaster® TLSZ guard locking switch functions by locking it actuator, which prohibits the opening of a guard.
The TLSZ uses radio frequency identification, RFID, coding to detect the appropriate target.
This version of the Guardmaster TLSZ guard locking switch features OSSD outputs. These outputs are enabled only when the actuator is locked and the RF target is sensed.
This device is intended to be part of the safety-related control system of a machine. Perform a risk assessment before installation to determine whether the specifications of this device are suitable for all operational and environmental characteristics of the machine. See Specifications on page 55 certification information and ratings.
Use nonremovable screws, bolts, or nuts to mount the switch and actuators. Do not over torque the mounting hardware.
TLSZ guard locking switches are classified according to ISO 14119 as Type 4 switching devices. The RFID targets are classified as having a high level of coding.
for
Measures are to be taken to minimize the need to defeat and to manage the use and availability of spare RFID targets.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 7
Chapter 1 General Description

Catalog Numbers

The schema for the TLSZ catalog number is shown in Ta b l e 1 . The parts of the schema are shown in Ta b l e 2
Table 1 - TLSZ Catalog Number Setup
440 G T Z S21 U P R H
1 234 5 6789
Table 2 - TLSZ Catalog Number Detail
Parameter Value Description
1 440 Safeguards the Product
2 G Guard locking switch
3 T Titan Locking Switch
4 Z PLe rated, cascadable safety signals
5 S21 Solid-state outputs, 2 safety (OSSD), 1 aux
6 U Unique coded RFID target
7PTAux signal shows lock status
8RLPower to Rele ase
9 H 8-pin M12 QD connector
.
Aux signal shows door status
Power to Lock
ATT EN TI ON : Guard lock switches that use the Power to Lock principle can only be used after a risk assessment has shown that the Power to Release principle is inappropriate for the application. If a power supply loss occurs with Power to Lock switches, the switches immediately become unlocked and the user may have access to the hazards.
8 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
General Description Chapter 1

Packaging Contents

Figure 1 shows the contents in the shipping package. The contents include:
•Switch
•Actuator
•RFID target
• T20 security Torx bit
• Two steel bolts and nuts
•Plug
• Installation instructions (not shown)
Figure 1 - Package Contents
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 9
Chapter 1 General Description
Notes:
10 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Installation
Chapter 2

General Considerations

Actuator/Target Mounting

The TLSZ guard locking switch is designed for use on guards that are engineered to be rigid and without sag. The TLSZ uses radio frequency identification, RFID, coding to detect the appropriate target.
Figure 2 shows the correct and incorrect ways to mount the target with the
actuator.
The TLSZ must only be used with the fully flexible actuator. The replacement part number for the actuator is catalog number 440G-A27143.
Figure 2 - Target/Actuator Mounting
Tar ge t
Actuator

Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 11
Chapter 2 Installation
This approach requires guide repositioning, see
page 14.
80 (3.19)
80 (3.19)80 (3.19)
80 (3.19)
1.5 mm (0.06 in.)

Allowable Approach Directions

The actuator and target must be always mounted as “close coupled” and can approach the switch in any of the three entry slot positions that are shown in
Figure 3
. Approach from the underside is not allowed, as the distance from the
target to the internal RF sensor is too far for reliable operation.
Figure 3 - Allowable Approach Direction

Minimum Operating Radius

When applied to hinged doors, the minimum operating distances along the length and perpendicular is shown in Figure 4
Figure 4 - Minimum Operating Distance [mm (in.)]
.
Figure 5 shows the location of the two 1.5 mm (0.06 in.) set screws that can be
adjusted to preset the actuator to an optimal angle, if needed.
Figure 5 - Actuator Set Screw
12 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Installation Chapter 2

Manual Release

The manual release feature only applies to TLSZR (Power to Release) switch. In some cases, you must manually release the locked actuator.
Figure 6
shows the two locations from which the actuator can be manually
released.
1. Remove the T20 Torx screw.
2. To release the actuator, insert a small screwdriver or rod in the hole.
If power is applied to the switch when the actuator is released, the OSSD safety outputs turn OFF and the switch goes to a faulted state with the status indicator flashing red at 4 Hz. Power then has to be cycled to the switch to return it to an operational state.
Figure 6 - Manual Release
3
1
2
T20

Manual Override Cover

2
≤ 2.5 (0.10) Ø
Figure 7 on page 14 shows an optional cover that is available only for the
TLSZR (Power to Release) switch. This cover has a lever that allows you to manually unlock the actuator at any time. Rotate the lever 90° to unlock the actuator.
If power is applied to the switch when the actuator is released, the OSSD safety outputs turn OFF, and the switch goes to a faulted state with the status indicator flashing red at 4 Hz. Power is then cycled to the switch to return it to an operational state.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 13
Chapter 2 Installation
1
1.2 N•m (10.62 lb•in)
2
90°
90°
Figure 7 - Manual Override Cover

Pair Proximity

Guide Repositioning

If a pair of TLSZ switches are mounted too close to each other, the two RF fields could interact causing crosstalk. Cross talk results in nuisance faults.
An absolute minimum of 200 mm (8 in.) must be used to help achieve correct operation.
The restriction also applies if a TLSZ switch is mounted close to the 440G-LZ guard locking and the 440N-Z SensaGuard™ switches.
The actuator guide can be repositioned to facilitate alignment of the actuator. In steps 8…11 (Figure 8
), rotate the metal guide to allow the switch body to be
fastened flush to the mounting surface.
Figure 8 - Guide Repositioning
2
3
1
5
6
4
7
8
14 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
18
10
9
11
Installation Chapter 2

Steel Locking Bolts

The TLSZ is assembled in the factory with plastic pins that secure the actuator guide. The plastic pins are rated for a holding force of 1500 N (337 lb). The plastic pins must be replaced with the steel bolts to achieve a holding force of 2000 N (585 lb). Figure 9
shows how to remove the cover to replace the blue
plastic pins with steel bolts.
Figure 9 - Steel Bolt Installation
1.2 N•m (10.62 lb•in.)
5 (0.20)
dia.
Steel bolts
2 x M5
1.4 N•m (12.39 lb•in.)
1.2 N•m (10.62 lb•in.)
2 x M5
1.4 N•m (12.39 lb•in.)
Plastic pins
15 (0.59)

Actuator Clearance

Fzh = 1500 N (337 lb)
Fzh = 2000 N (450 lb)
Figure 10 shows the clearance requirements for the TLSZ. The switch must
not be used as a guard stop. You must provide a mechanical stop at least 1mm (0.04 in.) away from the actuator guide. The actuator must be inserted within 4mm (0.16 in.) or less from the actuator guide to be sure it locks.
Figure 10 - Clearance and Insertion Distance
1…4 (0.04…0.16)
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 15
Chapter 2 Installation
As shown in Figure 11, the TLSZ has two slotted holes to facilitate installation. The slots allow up to 8 mm (0.31 in.) of movement of the switch body to achieve the proper clearance with the actuator.
1. Use the slotted holes for initial installation.
2. After alignment with the actuator, secure the switch body in place by adding mounting hardware in the circular holes.
3. To attain the maximum holding force, replace the plastic pins with steel screws inside the cover.
Figure 11 - Mounting Slots for Alignment [mm (in.)]
M5
12
3
Status/ Diagnostic
8 (0.31)
16 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Installation Chapter 2
86 (3.39)
57 (2.24)
3 (0.12)
3 (0.12)
6.5 (0.26)
17
(0.67)
21 (0.83)
14.5
(0.57)
52.5 (2.07)
31.5 (1.24)
60.5 (2.38)
67.5 (2.66)
6.5 (0.26)
5 (0.2)
M5 x 4
126 (4.96)
105 (4.13)
14 (0.55)
22 (0.87)
27 (1.06)
39 (1.54)
9 (0.35)
14 (0.55)
33 (1.3)
6.5 (0.26)
25.5 (1)
20.5 (0.81)
5 (0.2)
5.5 (0.22)
21
(0.83)
17 (0.67)
43 (1.69)
6 (0.24)
5 (0.2)
73 (2.87)
4 (0.16)
Status/ Diagnostic LED
Target Alignment Mark
14
(0.55)
2.2 (0.09)
24
(0.94)
4.2 (0.17)
19.2 (0.76)
M12
18
(0.71)
20
(0.79)
8
(0.31)
40 (1.57)
31 (4.22)
6.8
(0.27)
4 x 5.5 (0.22)
2 x M3
19
(0.75)
13
(0.51)
51
(2.0)
52 (2.05)
Actuator
Use with exible actuator only:
23.2 (0.91)
11.9
(0.47)
19
(0.75)
440G-ATZAE-xxxx
29.3 (1.15)
7
(0.28)
20
(0.79)
M5
5.5
(0.22)
Tar ge t
Connector location and

dimensions

Do not use cable gland knockouts, two places
Dimensions
Figure 12 shows the dimensions for the switch, target, and actuator.
Figure 12 - Dimensions [mm (in.)]
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 17
Chapter 2 Installation
3 x M5
5.5 (0.22)
6 (0.24)
20
(0.79)
86.5 (3.4)
35
(1.38)
40
(1.57)
13 (0.51)
19
(0.75)
6 (0.24)
7 (0.28)
Tar ge t
Actuator
Figure 13 shows the dimensions for mounting the target that is next to the
actuator.
Figure 13 - Actuator/Target Mounting Dimensions [mm (in.)]
18 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
+ 42 hidden pages